USERGUIDE

KBRG 225D AND 240D

This manualapplies tologic boardrevision “L”and newercontrolsonly.

See Page 2

© 1997 KB Electronics, Inc.

INSTALLATION AND OPERATING INSTRUCTIONS

REGENERATIVE DRIVEMODEL KBRG-225D

(P/N 8800)

MODEL KBRG-240D

(P/N 8802)

FULL WAVE • 4 QUADRANT

M1 M2L1 L2F+ F-

TB1

F1 F2

TB2

ARMATUREAC LINE FUSE FUSE

21 3 4 65

TB1

1297 8 10 11 13

J3

F1

(EARTH)

T1

GND

DBACCEL ACCELREVFWD

RESPSPDMAX

CLCLCOMPIR REV FWD

TCLJ8

NLT

S/LT

OFFSET

R33

ENFWD

REVEN

ONPWR

CL

See Safety Warning on Page 2

The information contained in this manual is intended to be accurate. However, the manufacturerretains the right to make changes in design which may not be included herein.

A COMPLETE LINE OF MOTOR DRIVES

™

ii

TABLE OF CONTENTS

Section Page

i. Simplified Setup and Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ii. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

II. Setting Mode of Drive (Speed or Torque Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

III. Setting Selectable Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

IV. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

V. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

VI. Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

VII. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

VIII. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

IX. Function Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

X. Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

TABLES

1. Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2. General Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3. Summary of Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4. Jumper J2 Position vs Motor Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5. Relationship of AC Line Input and Motor Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6. Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7. Field Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8. Control State vs Relay Contact State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

9. Armature Fuse Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

10. Current Limit Timer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

11. Parts List (Logic Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 17

12. Parts List (Power Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

FIGURES

1. Control Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2A. Linear Torque Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2B. Non-Linear Torque Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. AC Line Voltage Jumper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4. Motor Armature Voltage Jumper Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6. AC Line and Armature Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7A. Full Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7B. Half Voltage Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8. Main Speed Potentiometer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

9A. Voltage Following . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

9B. Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

9C. Start/Stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

9D. Alarm Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

9E. Tach-generator Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

10. Accel Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

11. Offset Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

12. Deadband Trimpot Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

13. Logic Board Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

14. Power Board Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1

i. KBRG SIMPLIFIED OPERATING INSTRUCTIONS

IMPORTANT – You must read these simplified operating instructionsbefore you proceed. These instructions are to be used as a referenceonly and are not intended to replace the detailed instructions providedherein. You must read the Safety Warning on page 2 before proceeding.

1. CONNECTIONS.

A. AC Line – Wire AC line voltage to terminals L1 and L2. Be sure jumpers J1A andJ1B are both set to the correct input line voltage of 115 or 230 VAC. Connectground wire (earth) to green ground screw.

B. Motor.1. Permanent Magnet (PM Type). Connect motor armature leads to M1+ and M2-.

Be sure jumper J3 is set to the proper position “90" for 90 volt DC motors and“180" for 180 volt DC motors. Note: 180 volt DC motors must be used with 230VAC line, 90 volt motors can be used with a 230 VAC or 115 VAC line. Note:Motor performance and efficiency, including brush life, may be adverselyaffected when using 90 volt motors with a 230 VAC line.

2. Shunt Wound Motors. Connect motor armature as above. Connect full voltageshunt field wires (90 volt motors with 100 volt fields and 180 volt with 200 voltfields) to F+ and F-. Connect half voltage field wires (90 volt motors with 50 voltfields and 180 volt motors with 100 volt fields) to F+ and L1.

2. SPEED OR TORQUE MODE.Jumper J7 is factory set for speed control operation (SPD). For torque control, set J7to TRQ position. Note: J8 must be set to the “S/LT” position for speed control operation.

3. MOTOR CURRENT.Jumper J2 is factory set for 15 amp motors (15A) on the KBRG-225D and 10 amp motors(10A) on the KBRG-240D. For lower amperage motors, place J2 in the proper position.If motor amperage is less than 2.5 amps, which is the lowest value on both models, usethe 2.5A position and readjust the IR and both CL trimpots according to section VIII Dand E on pages 14 and 15 .

Note: The factory setting for Current Limit is 150% of the nominal current setting (e.g.,if J2 is selected for 5 amps, the actual CL setting will be 7.5 amps).

4. TRIMPOT SETTINGS.All trimpots have been factory set in accordance with figure 1, page 3.

5. AC LINE FUSE.The power board on all models contains a single AC line fuse (F1), 25A for KBRG-225Dand 20A for KBRG-240D. The AC line fuse protects the unit from catastrophic failure.

6. ARMATURE FUSE.An armature fuse (F2) is also provided. A 25A armature fuse is installed on theKBRG-225D and a 20A on the KBRG-240D. It is recommended that the correct sizearmature fuse be installed depending on the rating of the motor and form factor. Seetable 9, page 13.

7. SIGNAL INPUT.Connect potentiometer or isolated analog input to terminal “10,” “11,” “12" and “13"according to section V, E and F, on pages 10 and 11. Do not ground (earth) signalinputs. Use a signal isolator when controlling multiple drives from a non isolated signalsource.

2

ii. SAFETY WARNING! — PLEASE READ CAREFULLY

This product should be installed and serviced by a qualified technician, electrician or

electrical maintenance person familiar with its operation and the hazards involved. Proper

installation, which includes wiring, mounting in proper enclosure, fusing or other overcurrent

protection and grounding, can reduce the chance of electric shocks, fires or explosion in this

product or products used with this product, such as electric motors, switches, coils, solenoids

and/or relays. Eye protection must be worn and insulated adjustment tools must be used when

working with control under power. This product is constructed of materials (plastics, metals,

carbon, silicon, etc.) which may be a potential hazard. Proper shielding, grounding and filtering

of this product can reduce the emission of radio frequency interference (RFI) which may

adversely affect sensitive electronic equipment. If information is required on this product,

contact our factory. It is the responsibility of the equipment manufacturer and individual installer

to supply this safety warning to the ultimate user of this product. (SW effective 11/92)

This control contains electronic Start/Stop and Inhibit circuits that can be used to start and

stop the control. However, these circuits are never to be used as safety disconnects since they

are not fail-safe. Use only the AC line for this purpose.

The input circuits of this control (potentiometer, start/stop, Inhibit) are not isolated from AC

line. Be sure to follow all instructions carefully. Fire and/or electrocution can result due

to improper use of this product.

This product complies with all CE directives pertinent at the time of manufacture.Contact factory for detailed installation instructions and Declaration of

Conformity. Installation of a CE approved RFI filter (KBRF-200A, KB P/N 9945C orequivalent) is required. Additional shielded motor cable and/or AC line cables may berequired along with a signal isolator (SI-4X, KB P/N 8801 or equivalent).

I. GENERAL INFORMATION.The KBRG is a full-wave regenerative control, capable of operating a DC motor (PermanentMagnet or Shunt) in a bidirectional mode. It provides 4-quadrant operation which allowsforward and reverse torque in both speed directions. The drive offers excellent controllability,which closely approximates the performance of servo-type drives. Ratings and specificationsare presented in tables 1 and 2. Be sure the drive is used within these ratings andspecifications.

(Note: Regenerative drives normally produce more motor heating than standardunidirectional SCR speed controls, especially under low speed operation. This shouldbe taken into consideration when specifying motor rating.)

WARNING! Be sure to follow all instructions carefully. Fire or electrocutioncan result due to improper use of this product. Read Safety Warning.

TABLE 1 – ELECTRICAL RATINGS

Model Part No.Input

Voltage(VAC)

Max. ACCurrent(RMS)

OutputVoltage(VDC)

Max. DCOutput

Current (ADC)

Max.Horsepower

HP, (KW)

KBRG-240D 8802115 16 0 – ±90 11 1, (.75)

230 16 0 – ±180 11 2, (1.5)

KBRG-225D 8800115 24 0 – ±90 16 1, (1)

230 24 0 – ±180 16 3, (2)

3

FIG. 1 – CONTROL LAYOUT

Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings

4

TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS

Parameter Specification Factory Setting

AC Line Input Voltage (VAC ±10%,50/60 Hz)

AC Line Frequency (Hz), # of PhasesArm Voltage Range at 115VAC Line (VDC)

Arm Voltage Range at 230VAC Line (VDC)Field Voltage at 115VAC Line (VDC)

Field Voltage at 230VAC Line (VDC)Service Factor

DutyMax Load Capacity (% for 2 minutes)

Ambient Temperature Range (ºC)Speed Range (Ratio)

Arm Feedback Load Regulation (% Base Speed)Tach Feedback Load Regulation (% Set Speed)

Line Regulation (% Base Speed)Current Ranges (ADC)

FWD and REV Accel Range (Secs.)Dead Band Range (% Base Speed)

Max Speed Trimpot Range (% Base Speed)IR Comp Range at 115VAC Line (VDC)

IR Comp Range at 230VAC Line (VDC)FWD and REV CL Range (% Range Setting)

Timed CL Range (Sec.)Voltage Following Input Range (VDC)

Voltage Following Linearity (% Base Speed)Tach-generator Voltage Input (Volts)

115 or 230

50/60, 10 – ±90

0 – ±180, 0 – ±90100/50

200/1001.0

Continuous150

0 – 50(1)

50:1

±1±1

±0.52.5, 5.0, 7.5, 10, 15(2)

0.1 – 150 – ±3

70 – 1100 – 15

0 – 300 – 150

1 – 150 – ±10, 0 – ±15

±0.57,20/30,50

230

——

0 – ±180—

——

——

——

——

—15 or 10

10

1005

10150

50 – ±15

—

50

Notes:(1) Control mounted in vertical position. Maximum ambient temperature in horizontal position is 45 ºC.(2) 15A current range on KBRG-225D only.

II. SETTING MODE OF DRIVE (SPEED OR TORQUE CONTROL).The KBRG can be operated as a speed control or torque control by setting the position ofjumper J7. The main speed potentiometer controls the magnitude of the mode selected. Setjumper J7 to "SPD" for speed control or to "TRQ" for torque control. (See fig. 1, p. 3.)

A. Speed Control Mode – When jumper J7 is set to the “SPD” position, the KBRG will varythe motor speed as a function of the voltage on input terminals "12" (signal) and "13"(common). IMPORTANT: When J7 is set for speed control (“SPD”), J8 must be set to“S/LT” position (factory setting). The input voltage can be derived from the wiper of themain speed potentiometer or from an isolated analog input (voltage following mode). Sincethe KBRG is a 4-quadrant regenerative drive, the motor speed will follow both a positiveand negative wiper voltage and drive the motor in both the forward direction and reversedirection. In addition, it will apply both forward and reverse torque in order to stabilize motorspeed.

To understand the concept of a regenerative drive, the operation of an elevator can be used.If one were to enter the elevator on the first floor and press 10, the motor and control wouldhave to lift the elevator against gravity. In this mode, the drive would operate like aconventional speed control which is called “motoring” (the applied load is opposite to thedirection of motor rotation). When the elevator is at floor 10 and floor 1 is pressed, gravity willtry to pull the elevator car down faster than the speed for which it is set. The control will thenprovide reverse torque to keep the car form falling faster than the set speed. This operationis regeneration (the applied load is in the same direction as the direction of motor rotation).Table 3 on page 5 summarizes the different modes of regen operation.

5

TABLE 3 – SUMMARY OF CONTROL OPERATION

QuadrantType of

OperationMotor Rotation

DirectionMotor Torque

DirectionApplied Load

Direction

I Motoring CW CW CCW

II Regeneration CCW CW CCW

III Motoring CCW CCW CW

IV Regeneration CW CCW CW

B. Torque Control Mode – When Jumper J7 is set to “TRQ” position, the KBRG will varymotor torque. The KBRG has been redesigned and now contains two (2) types of torquecharacteristics which are selectable with jumper J8. Speed/Linear Torque (S/LT) and NonLinear Torque (NLT). In the “S/LT” position (factory setting), both output torque andmotor speed vary linearly as a function of the input signal. The “S/LT” type of torque ismost suitable for take up and pay out winders where the speed and torque requirementsvary as the winder roll diameter changes. The “S/LT” torque characteristics are shown infig. 2A.

FIG. 2A – LINEAR TORQUE CURVE

In the “NLT” position, only torque (not speed) is varied by the input signal. The motoroutput torque remains constant over the motor’s full speed range unless the load is lessthan the set torque. If the load torque decreases below the set torque, the motor willrapidly increase to full speed. This type of torque control is applicable to processes wherethe torque must remain constant over a wide motor speed range. The “NLT” torquecharacteristics are shown in fig. 2B p. 6.

Because the KBRG is a regenerative control, torque will be applied in both forward andreverse directions. The maximum torque can be set with the FWD CL and REV CLtrimpots, and by using the FWD ACCEL and REV ACCEL trimpots, the rate of change oftorque can be made more or less gradual. The maximum speed trimpot can be used toset the maximum motor speed under a no load condition.

6

FIG. 2B – NON-LINEAR TORQUE CURVE

III. SETTING SELECTABLE JUMPERS.The KBRG has customer selectable jumpers which must be set before the control can be used(refer to fig. 1 p. 3). Bold indicates Factory Setting. (See sec. II, p. 4 for J7 and J8 settings.)

A. J1A, J1B - Input AC Line Voltage – Select proper input line voltage, 115VAC or 230VAC,by placing both jumpers (J1A and J1B) in the correct corresponding position, "115" or"230." See fig. 3.

B. J2 - Armature Current – Select the J2 position (2.5, 5, 7.5, 10, 15) closest to the ratedmotor current. (Note: The maximum output current is set to 150% of the J2 position, whichmay be readjusted using the FWD CL and REV CL trimpots.) Note: On ModelKBRG-240D, position 10A is factory setting.

TABLE 4 – JUMPER J2 POSITION vs MOTOR HORSEPOWER

Jumper J2 PositionMotor Current

(DC Amps)

Motor Horsepower

90VDC 180VDC

10A

5.0A

2.5A

7.5A

15AJ2 15A(1) 1 3

10A 1 2

7.5A 3/4 1

5.0A 1/2, 1/3 1, 3/4

2.5A 1/4 1/2

(1) 15A current range on KBRG-225D only.

C. J3 - Motor Armature Voltage – Select the desired armature voltage by placing J3 in theproper position, "90" or "180." Note: For 115 volt AC line input, the armature voltage mustbe set to "90." For 230 input, the armature voltage normally is set for "180." However, itis also possible to set the armature voltage to "90" for step-down operation.

7

FIG. 3 – AC LINE VOLTAGEJUMPER SETTING

FIG. 4 – MOTOR ARMATUREVOLTAGE JUMPER SETTING

115VAC 230VAC 90VDC 180VDC

TABLE 5 – RELATIONSHIP of AC LINE INPUT AND MOTORVOLTAGE with J1A, J1B and J3 JUMPER POSITION

AC INPUT VOLTAGEJ1A, J1BPOSITION

J3 POSITION MOTOR VOLTAGE

115 115 90 90

230 230 180 180

230 230 90* 90*

*A 90VDC motor can be used with a 230VAC line. However, speed range may be reduced andmotor overheating may result.

D. J4 - Tach-generator Voltage – (Note: Selection of the jumper position is not required ifarmature feedback is used.) Place J4 jumper in the position "7V", "20/30V," "50V" thatcorresponds to the tach-generator voltage in Volts/KRPM. Note: The tach voltage jumperposition is based on motor speed of 1,800 RPM.

For example, if the tach is 25V/KRPM and the motor speed is 3,600 RPM, use the "50V"J4 position. For other tach-generator voltages and motor speeds, an external resistor(RT) may be used as follows.

i. Install resistor in series with either tach-generator lead.ii. Place J4 in "7V" position.iii. The value of RT is calculated as follows.

RT = [(5.4 x Vt x S) - 68,000] VT = Tach voltage in volts/1000 RPMChoose the closest standard watt S = Base Speed of motor in RPMresistor value to the calculated value

E. J5 - Feedback Type – The KBRG can be operated in either armature feedback "AFB"or tach-generator feedback "TFB." Armature feedback provides adequate load regulationfor most applications. For very precise performance, tach-generator feedback "TFB"should be used. (Note: If tach feedback is desired, an external DC tach-generator mustbe used and connected as per instructions.) (See section V J, p. 12 for tach-generatorwiring.) (Note: The IR Comp trimpot must be set to the minimum setting [CCW] for tachfeedback.)

F. J6 - Current Limit (CL) Mode – The KBRG contains electronic current limiting that limitsthe maximum DC current to the motor. (Note: Current Limit is established with theselection of the J2 position and the setting of the Forward and Reverse CL trimpots "FWDCL" and "REV CL.")

8

Two modes of current limit are provided:

1. Timed Current Limit "TCL" – Turns the drive off after a preset time. (The time periodis adjustable with the TCL trimpot from 1-15 seconds and is factory set forapproximately 5 seconds.) In order for the Timed CL feature to operate, theStart/Stop circuit must be wired. To restart drive after it has "timed out," the Startbutton must be pressed.

Application Note: The “TCL” feature cannot be used in either torque mode, sincenuisance tripping will occur.

2. Non-Timed Current Limit "NTCL" – In this mode, the drive will reach preset CurrentLimit during overload and stay at that level until drive is turned "off" or fuse blows. IfNon-Timed CL is desired, move jumper J6 from the factory set "TCL" position to the"NTCL" position.

IV. MOUNTING.Mount the KBRG in a vertical position (connection terminals in down or up position) on a flatsurface free of moisture, metal chips, or corrosive atmosphere. (Note: If drive is mounted inother than a vertical position, decrease maximum allowable ambient temperature by 10 ºC.)(See Outline Drawing fig. 1, p. 3.) A 5K ohm Remote Speed potentiometer is provided witheach control. Install potentiometer using hardware provided. Be sure to install insulating diskbetween potentiometer and inside of front panel.

Enclosure – When mounting the KBRG in an enclosure, it must be large enough to allow forproper heat dissipation. A 12"x12"x24" enclosure is suitable for the KBRG-240D at full ratingand a 12"x24"x36" enclosure is suitable for the KBRG-225D at full rating. Smaller enclosuresmay be used if full rating is not required.

V. WIRING. Warning! Read Safety Warning before attempting to use this control.

Warning! To avoid erratic operation do not bundle AC Line and motor wires withpotentiometer, voltage following, enable, inhibit or other signal wiring. Use shieldedcables on all signal wiring over 12" (30 cm) – Do not ground shield.

Wire control in accordance with National Electric Code requirements and other local codesthat apply. The KBRG contains a single AC line fuse wired in series with terminal L1. Be sureto fuse each conductor which is not at ground potential (do not fuse neutral or groundedconductors). (See section VI, p. 12, for fuse information.) Wire control in accordance withconnection diagram (see fig. 8 and 9, p. 11). A separate AC line switch or contactor must bewired as a disconnect switch to control so that contacts open each ungrounded conductor.See table 6.

TABLE 6 – TERMINAL BLOCK WIRING INFORMATION

Terminal BlockDesignation

ConnectionDesignation

Supply Wire Gauge* Maximum TighteningTorque (lbs inch)Minimum Maximum

TB1 (Power Board) F+, F- 22 14 3.5

TB1 (Logic Board) Logic Connections 22 14 3.5

TB2 L1, L2, M1, M2 18 10 12

*AWG, Cu wire only.

A. AC Line – Connect AC line to terminals L1 and L2. (Be sure jumpers J1A and J1B areset to match the AC line voltage used. See table 4, p. 6.) See fig. 6, p. 10.

B. Motor Armature – Connect motor armature to terminal M1 and M2. (Be sure jumper J3is set to match motor voltage. See table 4, p. 6.) See fig. 6, p. 10.

9

FIG. 5 – MECHANICAL SPECIFICATIONS INCHES

[mm]

M1 M2L1 L2F+ F-

TB1

F1 F2

TB2

ARMATUREAC LINE FUSE FUSE

21 3 4 65 1297 8 10 11 13

F1

T1

R69

NOTE: CONTROL SHOWN ABOVE IS MODEL KBRG-225D.

10.00

(203.20)

(254.00)

8.00

(25.40)

(7.62)

1.00

0.30

DWG#: C3900-1-00096

(180.34)

7.70

7.10

(195.58)

3.440[87.4]

(4 PL)[R4.4]

R0.172

(4 PL)[R2.3]

R0.089

[8.2]0.324 (4 PL)

HEIGHT OF MODEL KBRG-240D IS 2.57" (65 mm).

10

FIG. 6 – AC LINE AND ARMATURE CONNECTIONC. Field (For Shunt Woundmotors only) – Do notuse F+ and F- terminals for anyother motor type. Connectmotor shunt field to terminalsF+ and F- for 90VDC motorswith 100VDC fields and180VDC motors with 200VDCfields. For motors with halfvoltage fields, 90VDC motorswith 50VDC fields and 180VDCmotors with 100 VDC fields,connect field to terminals F+ and L1. See table 7 forsummary of Field Connections.

CAUTION – Shunt-Wound motors may be damaged if field remains connectedwithout motor rotating for an extended period of time.

FIG. 7A – FULL VOLTAGE FIELD FIG 7B – HALF VOLTAGE FIELD

TABLE 7 – FIELD CONNECTIONS (Shunt Wound Motors Only)

AC Line Voltage (VAC) Motor Voltage Field Voltage (VDC) Field Connection

115 90 100 F+, F-

115 90 50 F+, L1

230 180 200 F+, F-

230 180 100 F+, L1

230 90* 100 F+, L1

*Step down operation (see sec. III C, p. 6).

D. Ground – Be sure to ground (earth) the control via green screw located on chassis.

E. Main Speed Potentiometer – The main speed potentiometer can be connected in severalways using terminals "10," "11," "12," "13." ( A 5K ohm potentiometer is supplied withcontrol. A 10K potentiometer can also be used.) [WARNING! Terminals “10,” “11,”“12" and “13" are not isolated from AC line. Do not ground (earth).]

i. Unidirectional operation only – Connect potentiometer to terminals "10," "12," "13" forforward direction. (To operate in reverse direction, connect to "11," "12," "13.")

ii. Bidirectional operation using reversing contacts – Connect to terminals "10," "11,""12," "13" as per fig. 8, p. 11.

iii. Bidirectional operation with potentiometer – Connect potentiometer to terminals "10,""11," "12" as per fig. 8, p. 11.

11

FIG. 9A – VOLTAGEFOLLOWING

FIG. 8 – MAIN SPEED POTENTIOMETER CONNECTIONS

FORWARD REVERSEBIDIRECTIONAL

with REVERSING CONTACTBIDIRECTIONALwith SPEED POT

F. Voltage Following – An isolated analog voltage can be used inlieu of main speed potentiometer. Connect signal to terminals "12"and "13." Note: Terminal "13" is common. A positive signal withrespect to terminal "13" will produce a positive output to motor. Anegative signal with respect to terminal "13" will produce anegative output. A 0 to ±10VDC is required to operate controlfrom 0 to ± full output. WARNING! Do not common multipledrives without a signal isolator. A bipolar signal isolator, SI-4X,is available as an option from your distributor.

G. Enable – Control may be electronically started and stopped withEnable circuit. Connect Enable contacts between terminals "8"and "9." When terminals "8" and "9" are joined, control is in"ENABLE" state. When terminals "8" and "9" are open, control is in "INHIBIT" state. (Seefig. 9B.)

IMPORTANT! If Enable is not used, a jumper must be installed between terminals"8" and "9" or control will not operate. (See Safety Warning on page 2.)

H. Start/Stop Circuit – A standard 3-wire start/stop circuit is provided (terminals "5," "6" and"7"). This allows a remote momentary 2-button start/stop station to be installed. In thismode, if AC power is removed, the start button must be used to restart the control. Also,when the control is in the Timed Current Limit mode (J6 set to TCL) and has "timed out,"it must be restarted using the start button. IMPORTANT! If the Start/Stop mode is notrequired, a jumper must be installed between terminals "5" and "7." (Note: The Timed CLfunction will operate only when the start/stop mode is used.) Control will not start usingStart/Stop circuit if AC line voltage is below 20% of nominal (95 volts on 115V circuit and190V on 230V circuit). (See Safety Warning on page 2.)

FIG. 9B – ENABLE FIG. 9C – START/STOP CIRCUIT

43

RY1

CONTACTSALARM

TB1

FIG. 9D – ALARM CONTACTS

12

FIG. 9E – TACH-GENERATORCONNECTION

I. Alarm Contacts – S.P.S.T. relay contacts (terminals "3" and "4") are used to signal awarning or to shut other equipment down if control goes to an Inhibit state. Rating ofcontacts are 1A-28VDC, .5A-115VAC. See table 8 for relay control state vs contact state.(See fig. 9D, p. 11.)

TABLE 8 – CONTROL STATE vs RELAY CONTACT STATE

Relay Contact State

Description of Control State Using Start / Stop Start / Stop Bypassed

No power to control O O

Power applied O X

Control in Stop mode O NA

Control is started with Start button X NA

Control has “Timed Out” in TCL O NA

O – Open, X – Closed, NA – Not Applicable

J. Tach-generator Input – Terminals "1" and "2" are usedto connect a DC tach-generator and should be used onlywhen control is in tach-generator feedback mode (J5 isin "TFB" position). Connect the positive (+) tach lead to terminal"1" and the negative (-) tach lead to terminal "2." Note: The tach-generator polarity must be phased so that the tach voltage is positive(+) on terminal "1" when the voltage on terminal "12" is positive (+).If the tach-generator is wired backwards, the control will run at fullspeed only.

VI. FUSING.

A. Power Board.

1. AC Line Fuse – The Power Board on all models contains a single AC line fuse (F1) 25Afor KBRG-225D and 20A for KBRG-240D) which protects the unit from catastrophicfailure. CAUTION: Most electrical codes require that each ungrounded conductorcontain fusing. Separate branch circuit fusing may be required. Check local electricalcodes.

2. Armature Fuse – An armature fuse (F2) is also provided with a rating equal to themaximum RMS rating of the control. It is recommended that the correct size armaturefuse be installed, depending on the rating of the motor and form factor (RMS/AVGcurrent). Fuse type should be Littlefuse 326 ceramic or Buss ABC, or equivalent. Afuse chart is presented on page 13 (table 9) which suggests appropriate armature fuseratings. However, the specific application may require larger fuse ratings based onambient temperature, CL set point and duty cycle of operation (see table 9, p. 13).Fuses may be purchased from your distributor.

B. Control Board Fuse – The logic control board contains a low amperage fuse (.150 ampLittelfuse 3AG normal blo or equivalent) which protects the control transformer and othercomponents against catastrophic failure. Under normal circumstances, this fuse shouldnever blow. (See fig. 1, p. 3, for location.)

VII. OPERATION.

WARNING! Read Safety Warning on page 2 before attempting to operate orsevere injury or death can result.

After the KBRG has been set up (Jumpers are in appropriate position) and the drive has beenproperly wired, the startup procedure can begin. Before initially starting, be sure main speedpot is in minimum position. (Set main speed pot to full CCW position if wired for unidirectionaloperation and to center position if wired for bidirectional control. (See fig. 8, p. 11.)

13

FIG. 10 – ACCEL TRIMPOT ADJUSTMENT

TABLE 9 – ARMATURE FUSE CHART (F2 Power Board)

Motor Horsepower Approx. DC MotorCurrent Amps

Fuse Rating(AC Amps)90VDC 180VDC

1/8 1/4 1.3 2

1/6 1/3 1.7 2

1/4 1/2 2.5 4

1/3 3/4 3.3 5

1/2 1 5.0 8

3/4 1 7.5 12

1 2 10.0 15, 20*

1 3 15.0 25

* Use higher rated fuse for high ambient temperature or when rapid starting and stopping occur.

Start control by applying AC power. Enable circuit must be closed for control to start (jumperterminals "8" and "9"). If wired for start/stop operation, press start switch. If not wired forstart/stop, terminals "5" and "7" must be jumpered. Rotate main speed potentiometer to controlmotor speed.

VIII. TRIMPOT ADJUSTMENTS.The KBRG contains many trimpots which have been factory adjusted for most applications.(See table 2, p. 4. for factory settings.) (Note: fig. 1, p. 3 presents the various trimpots withtheir locations. They are shown in the approximate adjustment position.) Some applicationsmay require readjustment of trimpots in order to tailor control to exact requirements. Readjusttrimpots as follows:

A. Forward Acceleration (FWD ACCEL) and Reverse Acceleration (REV ACCEL) – TheFWD ACCEL trimpot determines the amount of time it takes the control voltage to reachfull output in the forward direction. It also determines the amount of time it takes for thecontrol voltage, in the reverse direction, to reach zero output. (FWD ACCEL also sets theReverse Decel.)

The REV ACCEL trimpot determines the amount of time it takes the control voltage toreach full output in the reverse direction and the time it takes for the control voltage, in theforward direction, to reach zero output. (REV ACCEL is the Forward Decel.)

The FWD and REV ACCEL trimpots are factory adjusted to 1 second. The accelerationtimes are adjustable to a maximumof 15 seconds. (See fig. 10 forgraphic representation of ACCEL.)

Note: The FWD and REV CL trim-pots settings may override therapid accel and decel settings.

Note: A 4-quadrant ACCEL/DECEL accessory module isavailable as an option. It providesseparate control of FORWARDacceleration and deceleration andREVERSE acceleration anddeceleration.

14

FIG. 11 – OFFSET TRIMPOT ADJUSTMENT

FIG. 12 – DEADBAND TRIMPOT ADJUSTMENT

B. Offset (OFFSET) – This trimpotdetermines the amount of bias in theforward or reverse direction. Thetrimpot is factory set to provide ap-proximately zero offset, whichmeans neither the forward nor thereverse speed is favored. (See fig.11 which illustrates the action of theOFFSET trimpot.)

C. Deadband (DB) – The DB trimpotsets the amount of main speed po-tentiometer rotation required to initi-ate control voltage output. It is fac-tory adjusted to approximately 25%of rotation.

The DB trimpot also determines theamount of delay that will occur be-fore regeneration starts. (Regenera-tion occurs when the applied loadtorque is in the same direction asthe motor rotation.)

To readjust the DB to factory setting:

i. Set Main Speed pot to zerospeed position.

ii. Set DB trimpot to full CCW posi-tion.

iii. Adjust DB trimpot CW until mo-tor hum is eliminated.

(See fig. 12 for graphic illustra-tion of the DB trimpot.)

Note: If the deadband trimpot is set too low (CCW direction), the motor may oscillatebetween forward and reverse. Adjust deadband trimpot CW until the instabilitydisappears. (Oscillation may also occur due to response setting. See section VIII, G, p.15.)

D. Forward Current Limit (FWD CL) and Reverse Current Limit (REV CL) Trimpots –These trimpots are used to set the maximum amount of DC current that the motor candraw in both the forward and reverse directions. The amount of DC current determinesthe amount of maximum motor torque in both the Speed Control Mode and Torque ControlMode. They are factory set at 150% of the current established by the jumper J2 setting.Readjust the CL trimpots as follows:

i. Turn CL trimpot to MIN (CCW) position. Be sure jumper J2 is in proper positionapproximately equal to the motor DC ampere rating.

ii. Wire in a DC ammeter in series with armature lead. Lock shaft of motor.

iii. Apply power. Rotate CL trimpot CW until desired CL setting is reached (factorysetting is 1.5 times rated motor current). Be sure control is in Forward direction forFWD CL trimpot adjustment and likewise with REV CL.

WARNING! Do not leave motor shaft locked for more than 2 – 3 seconds to preventmotor damage.

CAUTION: Adjusting the CL above 150% of motor rating can cause overheating anddemagnetization of some PM motors. Consult motor manufacturer.

15

E. IR Compensation (IR Comp) – The IR Comp is used to stabilize motor speed undervarying loads. (Note: If control is in Tach Feedback mode, the IR Comp should be setto minimum - CCW.)

Readjust the IR Comp trimpot as follows:

i. Run motor at approximately 30-50% of rated speed under no load and measure actualspeed.

ii. Load motor to rated current. Rotate IR Comp trimpot so that loaded speed is thesame as the unloaded speed measured in the previous step.

Control is now compensated so that minimal speed change will occur over a wide rangeof motor load. [Note: Too much IR Comp will cause unstable (oscillatory) operation.]

F. Maximum Speed (MAX) – The MAX trimpot is used to set the maximum output voltageof the control which, in turn, sets the maximum speed of the motor. In the Torque ControlMode, the MAX trimpot setting determines the unloaded motor speed. Adjust the MAXtrimpot as follows:

i. Rotate Main Speed potentiometer to full speed (CW).

ii. Adjust MAX trimpot to desired maximum motor speed.

(Note: Do not exceed maximum rated RPM of motor since unstable operation may result.)

G. Response (RESP) Trimpot – This trimpot determines the dynamic response of the control.The factory setting is approximately 50% of full rotation. The setting may be increased ifa faster response is required. (Note: If response is made too fast, unstable operation mayresult.)

H. Timed Current Limit (TCL) Trimpot – Trimpot is functional only when control is wired for3-wire Start/Stop and J6 is in the TCL position. The TCL trimpot sets the delay time for theTimed Current Limit. The trimpot is adjustable over a time range of 1-15 seconds and isfactory set for approximately 5 seconds. Calibrate the TCL trimpot by setting the trimpotto the approximate desired delay time as follows: (See table 10.)

TABLE 10 – CURRENT LIMIT TIMER SETTINGS

Approx. Trip Time(Secs)

Trimpot Position

1 Full CCW

8 Midway

15 Full CW

IX. FUNCTION INDICATOR LAMPS.

A. LED 1 Power On (PWR ON) – Indicates that the drive is energized with the AC line.

B. LED 2 Current Limit (CL) – Indicates that the drive is in Current Limit. If set in the timedCurrent Limit mode (J6 set to "TCL") and has "timed out," the LED 2 will remain ON untilthe drive is restarted.

C. LED 3 Forward Enable (FWD EN) – Indicates that the drive is engaged in the forwarddirection. [Enable circuit closed (terminals "8" and "9" joined), the start circuit initiated anda "forward" speed command.] The FWD EN lamp will also be lighted in the reverse directionif the control is in regeneration.

D. LED 4 Reverse Enable (REV EN) – Indicates that the drive is engaged in the reversedirection. [Enable circuit closed (terminals "8" and "9" joined), the start circuit initiated anda "reverse" speed command.] The REV EN lamp will also be lighted in the forward directionif the control is in regeneration.

X – LIMITED WARRANTY

For a period of 18 months from date of original purchase, KB will repair or replace without

charge devices which our examination proves to be defective in material or workmanship.

This warranty is valid if the unit has not been tampered with by unauthorized persons,

misused, abused, or improperly installed and has been used in accordance with the

instructions and/or ratings supplied. The foregoing is in lieu of any other warranty or

guarantee, expressed or implied, and we are not responsible for any expense, including

installation and removal, inconvenience, or consequential damage, including injury to any

person, caused by items of our manufacture or sale. Some states do not allow certain

exclusions or limitations found in this warranty so that they may not apply to you. In any

event, KB's total liability, under all circumstances, shall not exceed the full purchase price

of this unit. (rev 4/88)

KB ELECTRONICS, INC.12095 NW 39th Street, Coral Springs, FL 33065 • (954) 346-4900 • Fax (954) 346-3377Outside Florida Call TOLL FREE (800) 221-6570 • E-mail – info@kbelectronics.com

www.kbelectronics.com

(A40260) – Rev. C – 1/98